Method and device for stabilization of pile goods such as pile carpet with a reinforcing back and pile goods

ABSTRACT

A pile carpet after tufting or the like is usually provided on the back with a latex precoat for stabilization and then provided with a foam back or an additional jute fabric. This environmentally hazardous method and the problem of recycling the foam back as well as the latex layer can be avoided If a nonwoven is applied instead to the tufted back of the carpet by water needling. This is possible with water needling in that the solidification of the pile fibers in or on the primary carrier takes place but no nonwoven fibers reach the visible side of the carpet. The back layer to be needled can also be made thicker and mote voluminous. Instead of a carpet, any other pile goods can also be stabilized in this fashion.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a divisional application of U.S. Ser. No. 09/649,571, filed Aug. 29, 2000 now U.S. Pat. No. 6,594,874.

The back, for example of a tufted carpet, must serve primarily for firmly holding the pile fibers, since in tufting the pile fibers are placed in the primary carrier but can be pulled out easily once again. The back of the carpet must also provide a greater volume, a soft step, and good installation ability with dimensional stability. It is known that these conditions can be produced with a precoat made of latex which must cure. As the second coat, a jute cloth could then be applied. The second layer should also consist of a foam that must be vulcanized. These manufacturing methods are very costly and the product thus produced is environmentally hazardous when disposed of later.

The goal of the invention is to find a method with which the environmentally hazardous binder, foam, and required chemicals can be avoided. At the same time, the pile goods product, especially a carpet manufacturing system, must become cheaper and yet the pile goods must have all the necessary qualities.

To achieve this goal, provision is made such that preferably a nonwoven is fastened by hydrodynamic water needling to the back of a primary carrier that holds the pile fibers. It has been found that in water needling the fibers of the stabilizing nonwoven can be shot into the back of the primary carrier and into the pile fibers held there far enough that parts of the nonwoven that have a stabilizing effect are visible on the exterior of the pile, or on the roots of the pile of the web goods. The nonwoven is needled only with the pile fibers visible on the back side and reversed there and with the back of the primary carrier so that the pile fibers are stabilized in the back.

It is true that in practice a more stable and possibly also a more voluminous carpet is desirable than one that has only a lightweight nonwoven on the back. It is therefore advantageous in designing the method if a composite made of a lightweight nonwoven, a coarsely braided, dimensionally stable stability area element, and possibly also a lightweight nonwoven are combined and laid on the non-solidified back of the carpet and then connected in one work step with the back of the carpet using hydrodynamic water needling. Now the carpet has not only a solidified pile permanently held in the back but also the desired volume and, with the stability area element, the required dimensional stability as well. Such a stabilizing back layer can weigh up to 600 g/m².

Using the method according to the invention, a pile carpet with the desired quality properties can be manufactured more economically, one that has no chemicals relative to the design of the back so that recycling no longer poses any problems.

As a nonwoven for stabilizing the pile fibers, a carded nonwoven should be used which can be done without solidification and possibly also slight pre-solidification using water needling, and placed on the back of the primary carrier. Polyester, PP, PA, or other fibers can be used as the fibers. The nonwoven can have its thickness and weight adapted to the specific requirements and it should preferably have a weight of 100–200 g/m². Then this web material should pass beneath the beam of a water needling machine with the water pressure adjusted so that the fibers of the nonwoven are woven once, in other words the nonwoven or the composite acquires greater strength, but at the same time its fibers penetrate into the pile fibers bent in the back of the web goods and penetrate the primary carrier so that the pile web goods are stabilized without the pile being changed in any way. The water pressure must be adapted to the individual conditions. Pressures up to 600 bars can be used.

In the drawing, a machine is shown schematically as an example with which such web goods back solidification can be performed.

On reel 1, a web-shaped pile goods 14 is wound so that the visible side or the pile side, is directed downward. Web goods 14 can be a tufted carpet, plush goods, or other web goods that have a velvety surface. These web goods 14 run continuously through a water needling machine 5 which here consists of only a drum 6, which has only one water beam 7 above the drum. The web goods thus has the pile resting on drum 6. Before the web goods enter the hydrodynamic solidification device 5, its back side is covered with a nonwoven. This nonwoven is placed on the reel located above the advancing pile goods and unrolls at a constant speed that conforms to the speed of the pile goods. By means of hard water needling, the nonwoven is solidified in device 5, and its fibers are moved into the back and thus into the unbent pile fibers of the web goods as well. The pile fibers are thus held firmly in the primary carrier without having to be fixed by a latex precoating in the back. Water needling machine 5 can also consist of several drums 6 or an endless belt at which several water beams 7 are directed from above. Then the carpet or the like must be dried, which in this example can tie performed with an aerating screen drum dryer 8, since the web goods are still permeable to air. The screen drum dryer 8, as is known, consists of a drum 10 rotatably mounted in a housing 9 and associated endwise with a fan 11, which circulates the processing air over cover 12 in a circuit. The finished carpet is then wound upon reel 13.

The back layer of carpet to be applied can be a simple lightweight carded nonwoven with winder 2 or can consist of a composite that consists of two or three stabilizing web-shaped goods. For this purpose, winding rollers 3 and 4 are shown in the drawing and are likewise located outside the pile goods 14 next to reel 2. Dimensionally stable web goods made of a coarsely woven fabric or the like can leave reel 3 and a lightweight carded nonwoven can be unreeled from reel 4. All in all, they travel as the new back layer together with pile goods 14 into device 5 and are needled there firmly to the back of the pile goods. The goods supplemented in this manner are dimensionally stable and have a soft back as well as a pile anchored firmly in the back, which is not changed in its appearance by this solidification process. 

1. Web form goods, consisting of a pile placed in a primary carrier and a back layer which anchors the pile to the back of the primary carrier, characterized in that the primary carrier serves to hold the pile fibers by means of a nonwoven back layer which is connected with the back of the primary carrier by water needling so that back ends of the pile fibers are held in the primary carrier and stabilized.
 2. Web goods, consisting of a pile applied to a primary carrier and a back layer provided on the back of the primary carrier to anchor the pile, characterized in that the back layer consists of at least one lightweight nonwoven and a coarsely woven fabric or at least one lightweight nonwoven, wherein the back layer is held by water needling to back ends of the pile fibers held in the primary carrier and to the primary carrier.
 3. Web goods comprising: a primary carrier having a back side and an exterior side; a pile placed in the primary carrier; and a back layer comprising a nonwoven provided on the back side of the primary carrier and connected to the primary carrier by water needling; wherein the pile is held in the primary carrier by the back layer without a solidified chemical binder.
 4. Web goods according to claim 3, wherein fibers of the nonwoven are visible on the exterior side of the back layer.
 5. Web goods according to claim 3, wherein the back layer comprises a composite of at least one lightweight nonwoven and a coarsely woven fabric.
 6. Web goods consisting essentially of: a primary carrier having a back side and an exterior side; a pile placed in the primary carrier; and a nonwoven back layer provided on the back side of the primary carrier and connected to the primary carrier by water needling, wherein the pile is held in the primary carrier by the back layer without a solidified chemical binder.
 7. Web goods according to claim 6, wherein fibers of the nonwoven are visible on the exterior side of the back layer.
 8. Web goods according to claim 6, wherein the back layer consists essentially of a composite of at least one lightweight nonwoven and a coarsely woven fabric. 